Reinforced insulating panel and method of manufacturing same

ABSTRACT

A reinforced insulating panel comprises an insulating foam slab, and at least one reinforcement sheet disposed on a respective face of the insulating foam slab. Each reinforcement sheet comprises a plurality of continuous fibers extending diagonally across the insulating foam slab.

FIELD OF THE INVENTION

The present invention relates generally to building structures and inparticular, to a reinforced insulating panel and method of manufacturingsame.

BACKGROUND OF THE INVENTION

In the field of building and construction, the light-frame constructionmethod, sometimes referred to as “stick framing” or “stickconstruction”, is commonly used for constructing small- to medium-sizedbuildings, such as for example houses. Walls that are constructed usingthis method typically comprise a series of vertically-oriented framemembers, such as lumber “studs”, that are joined byhorizontally-oriented frame members, such as lumber “header” plates andlumber “footer” plates. For exterior walls, a layer of rigid boards,such as plywood boards or oriented strand board (OSB) boards, is usuallyfastened to exterior-facing sides of the frame members to increase thestructural rigidity of the wall. A layer of insulating material, such asfor example slabs of expanded polystyrene (EPS) foam, is then fastenedto the rigid boards to provide thermal insulation. A weather barrier,such as for example a polymer film, is then affixed to the layer ofinsulating material to provide a barrier to liquid.

For example, FIG. 1 shows a portion of a prior art exterior wall 10constructed using the light-frame construction method. The wall 10comprises a series of vertically-oriented frame members, namely lumberwall studs 12, that are joined by lumber header plates (not shown) andlumber footer plates (not shown). The wall 10 also comprises a pluralityof OSB boards 14 fastened to exterior-facing sides of the studs 12, anda layer of insulating material slabs 16 fastened to the OSB boards 14for providing thermal insulation. The wall 10 further comprises aweather barrier 18 affixed to the insulating material slabs 16 forproviding a barrier to liquid. Interior finishing materials (not shown),such as for example drywall boards, may then be fastened to theinterior-facing sides of the studs 12, and exterior finishing materials(not shown), such as for example masonry or brickwork, may beconstructed adjacent the exterior-facing surface of the wall 10.

Improvements are generally desired. It is therefore an object of thepresent invention at least to provide a novel reinforced insulatingpanel and method of manufacturing same.

SUMMARY OF THE INVENTION

At the time of writing, many North American building codes are beingupdated to require that exterior walls of buildings constructed usingthe light-frame construction method include some form of diagonalbracing. There is therefore a general need for building materials thatinclude some form of diagonal bracing.

Accordingly, in one aspect there is provided a reinforced insulatingpanel comprising: an insulating foam slab; and at least onereinforcement sheet disposed on a respective face of the insulating foamslab, each reinforcement sheet comprising a plurality of continuousfibers extending diagonally across the insulating foam slab.

The continuous fibers may extend between diagonally opposite corners ofthe face and between adjacent edges of the face.

The reinforcement sheet may comprise at least one film and thecontinuous fibers. The at least one film may comprise a single film. Thecontinuous fibers may be disposed between the single film and theinsulating foam slab. The single film may be disposed between thecontinuous fibers and the insulating foam slab. The single film may beadhered to the insulating foam slab. The single film may be metallized.The single film may be perforated. The at least one film may comprise afirst film and a second film, the continuous fibers being disposedbetween the first film and the second film. At least one of the firstfilm and the second film may be adhered to the insulating foam slab. Atleast one of the first film and the second film may be metallized. Atleast one of the first film and the second film may be perforated.

The at least one reinforcement sheet may comprise a single reinforcementsheet joined to a first face of the insulating foam slab, and whereinthe panel further comprises a backing sheet joined to a second face ofthe insulating foam slab. The first face and the second face may beopposite faces of the insulating foam slab.

The at least one reinforcement sheet may comprise a first reinforcementsheet disposed on a first face of the insulating foam slab and a secondreinforcement sheet disposed on a second face of the insulating foamslab. The first face and the second face may be opposite faces of theinsulating foam slab.

The plurality of continuous fibers may comprise parallel continuousfibers. The parallel continuous fibers may be uniformly spaced. Theparallel continuous fibers may have a pitch of less than about 0.4inches. The parallel continuous fibers may have a pitch of less thanabout 0.25 inches. The parallel continuous fibers may define an angle ofabout 26.6 degrees relative to a longitudinal side of the panel. Theparallel continuous fibers may be arranged as a diagonal grid. Theparallel continuous fibers may comprise a first set of parallelcontinuous fibers and a second set of parallel continuous fibers. Thefirst set of parallel continuous fibers may have a different diagonalorientation than the second set of parallel continuous fibers. Thefibers of the first set may define an angle of about 53.1 degreesrelative to the fibers of the second set.

The continuous fibers may be fabricated of any of glass, metal, polymer,plastic, and wool.

The insulating foam slab may be fabricated of any of expandedpolystyrene foam, extruded polystyrene foam, and polyurethane foam.

In another aspect, there is provided a method of manufacturing areinforced insulating panel, the method comprising: providing aninsulating foam slab; providing at least one reinforcement sheet, eachreinforcement sheet comprising a plurality of continuous fibers; andaffixing each reinforcement sheet to a respective face of the insulatingfoam slab such that the continuous fibers are oriented diagonally acrossthe insulating foam slab.

The method may further comprise, prior to the affixing, orienting thereinforcement sheet such that the continuous fibers are oriented toextend between diagonally opposite corners of the face and betweenadjacent edges of the face.

The reinforcement sheet may comprise at least one film and thecontinuous fibers. The at least one film may comprise a single film. Thecontinuous fibers may be disposed between the single film and theinsulating foam slab. The single film may be disposed between thecontinuous fibers and the insulating foam slab. The single film may beadhered to the insulating foam slab. The single film may be metallized.The single film may be perforated. The at least one film may comprise afirst film and a second film, the continuous fibers being disposedbetween the first film and the second film. At least one of the firstfilm and the second film may be adhered to the insulating foam slab. Atleast one of the first film and the second film may be metallized. Atleast one of the first film and the second film may be perforated.

The at least one reinforcement sheet may comprise a single reinforcementsheet, the method further comprising: affixing a backing sheet to arespective face of the insulating foam slab.

The plurality of continuous fibers may comprise parallel continuousfibers. The parallel continuous fibers may be uniformly spaced. Theparallel continuous fibers may have a pitch of less than about 0.4inches. The parallel continuous fibers may have a pitch of less thanabout 0.25 inches. The parallel continuous fibers may define an angle ofabout 26.6 degrees relative to a longitudinal side of the panel. Theparallel continuous fibers may be arranged as a diagonal grid. Theparallel continuous fibers may comprise a first set of parallelcontinuous fibers and a second set of parallel continuous fibers. Thefirst set of parallel continuous fibers may have a different diagonalorientation than the second set of parallel continuous fibers. Thefibers of the first set may define an angle of about 53.1 degreesrelative to the fibers of the second set.

The continuous fibers may be fabricated of any of glass, metal, polymer,plastic, and wool.

The insulating foam slab may be fabricated of any of expandedpolystyrene foam, extruded polystyrene foam, and polyurethane foam.

The providing the insulating foam slab may further comprise molding theinsulating foam slab.

The providing the at least one reinforcement sheet may further compriseforming the at least one reinforcement sheet. The forming may comprisedisposing the continuous fibers and at least one glue layer between afirst film and a second film. The forming may comprise disposing thecontinuous fibers and at least one glue layer against a film. Disposingthe continuous fibers may further comprise disposing each fiberindividually or disposing two or more continuous fibers simultaneously.The forming may further comprise orienting the continuous fibers so asto have a suitable diagonal orientation.

In another aspect, there is provided a method of manufacturing areinforced insulating panel, the method comprising: providing aninsulating foam slab; and affixing a film to a face of the insulatingfoam slab, and affixing a plurality of continuous fibers to the film,the continuous fibers being oriented so as to be oriented diagonallyacross the face of the insulating foam slab, or affixing a plurality ofcontinuous fibers to a face of the insulating foam slab, the continuousfibers being oriented so as to be oriented diagonally across the face ofthe insulating foam slab, and affixing a film to the continuous fibers.

The method may further comprise, where the continuous fibers have beenaffixed to the film that has been affixed to the insulating foam slab,affixing an additional film to the continuous fibers.

Affixing the continuous fibers may further comprise orienting thecontinuous fibers so as to have a suitable diagonal orientation.

Affixing the continuous fibers may further comprise orienting thecontinuous fibers such that the continuous fibers are oriented to extendbetween diagonally opposite corners of the face and between adjacentedges of the face.

Affixing the continuous fibers may further comprise affixing each fiberindividually or affixing two or more continuous fibers simultaneously.

One or more of the film and the additional film may be metallized. Oneor more of the film and the additional film may be perforated.

The method may further comprise: affixing a backing sheet to an oppositeface of the insulating foam slab. The backing sheet may be metallized.The backing sheet may be perforated.

The plurality of continuous fibers may comprise parallel continuousfibers. The parallel continuous fibers may be uniformly spaced. Theparallel continuous fibers may have a pitch of less than about 0.4inches. The parallel continuous fibers may have a pitch of less thanabout 0.25 inches. The parallel continuous fibers may define an angle ofabout 26.6 degrees relative to a longitudinal side of the panel. Theparallel continuous fibers may be arranged as a diagonal grid. Theparallel continuous fibers may comprise a first set of parallelcontinuous fibers and a second set of parallel continuous fibers. Thefirst set of parallel continuous fibers may have a different diagonalorientation than the second set of parallel continuous fibers. Thefibers of the first set may define an angle of about 53.1 degreesrelative to the fibers of the second set.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described more fully with reference to theaccompanying drawings in which:

FIG. 1 is a sectional plan view of a portion of a prior art wall;

FIG. 2 is a perspective view of a reinforced insulating panel;

FIG. 3 is a front elevational view of the reinforced insulating panel ofFIG. 2;

FIG. 4 is side view of the reinforced insulating panel of FIG. 2;

FIG. 5 is an end view of the reinforced insulating panel of FIG. 2;

FIG. 6 is a rear elevational view of the reinforced insulating panel ofFIG. 2;

FIG. 7 is an enlarged fragmentary view of a portion of the reinforcedinsulating panel of FIG. 3 identified by reference numeral 7;

FIG. 8 is an enlarged fragmentary view of a portion of the reinforcedinsulating panel of FIG. 6 identified by reference numeral 8;

FIG. 9 is an exploded view of a portion of a reinforcement sheet formingpart of the reinforced insulating panel of FIG. 2; and

FIG. 10 is a sectional plan view of a portion of a wall incorporatingthe reinforced insulating panel of FIG. 2.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Turning now to FIGS. 2 to 9, a reinforced insulating panel is shown andis generally indicated by reference numeral 20. Panel 20 is configuredto be fastened to exterior-facing sides of frame members of an exteriorwall of a building constructed using the light-frame constructionmethod.

Panel 20 comprises a generally planar insulating foam slab 22 having amonolithic shape and defining opposing faces, namely a first face 24 anda second face 26. In this embodiment the insulating foam slab 22 isfabricated of molded expanded polystyrene (EPS) foam, and has alongitudinal shape having dimensions of 4 feet×8 feet×1 inch.

The panel 20 further comprises a reinforcement sheet 30 disposed on thefirst face 24 of the insulating foam slab 22. In the embodiment shown,the reinforcement sheet 30 comprises two (2) polymer films, namely afirst film 32 and a second film 34, and a plurality ofdiagonally-oriented continuous fibers 40 disposed between the first film32 and the second film 34 in a “sandwich” configuration.

In this embodiment, the continuous fibers 40 are arranged as two (2)sets of parallel continuous fibers, namely a first set 52 of parallelcontinuous fibers and a second set 54 of parallel continuous fibers.Each set 52 and 54 of parallel continuous fibers is oriented in arespective diagonal orientation, and with each continuous fiber 40 ofeach set 52 and 54 being sized so as to extend diagonally across thefirst face 24. In this embodiment, the continuous fibers 40 within eachset 52 and 54 of parallel continuous fibers are uniformly spaced andhave a pitch of about 0.25 inches, and are fabricated of glass. Thecontinuous fibers 40 are oriented so as to extend between diagonallyopposite corners of the first face 24 and between adjacent edges of thefirst face 24. As a result of this orientation and the dimensions of theinsulating foam slab 22, in this embodiment, the fibers 40 define anangle θ of about 26.6 degrees relative to the longitudinal side of thepanel 20, as may be seen in FIG. 7, and the fibers of set 52 define anangle of about 53.1 degrees relative to the fibers of set 54.

At least one glue layer (not shown) is disposed generally between thefirst film 32 and the second film 34 for joining the first film 32, theplurality of continuous fibers 40, and the second film 34 within thereinforcement sheet 30. A glue layer (not shown) is also disposedbetween the second film layer 34 and the first face 24 for bonding thereinforcement sheet 30 to the insulating foam slab 22. As will beunderstood, as a result of this bonded construction, the panel 20advantageously has a generally integrated, unitary structure. In thisembodiment, the first film 32 and the second film 34 are fabricated ofpolypropylene.

The panel 20 also comprises a backing sheet 60 disposed on the secondface 26 of the insulating foam slab 22. In this embodiment, the backingsheet 60 comprises a single film, and is fabricated of polypropylene. Aglue layer (not shown) is disposed between the backing sheet 60 and thesecond face 26 for bonding the backing sheet 60 to the insulating foamslab 22.

FIG. 10 shows a portion of an exterior wall incorporating the panel 20,and which is generally indicated by reference numeral 70. Wall 70 formspart of an exterior wall of a building, such as for example a house,constructed using the light-frame construction method. The wall 70comprises a plurality of vertically-oriented frame members 72 that arejoined by a plurality of horizontally-oriented frame members (notshown). In this embodiment, the vertically-oriented frame members 72 arelumber wall studs, and the horizontally-oriented frame members are belumber header plates (not shown) and lumber footer plates (not shown).The wall 70 further comprises a plurality of panels 20 fastened toexterior-facing sides of the vertically-oriented frame members 72 andthe horizontally-oriented frame members by fasteners (not shown). Inthis embodiment, the fasteners are screws. As may be seen in FIG. 10,the panels 20 are fastened such that the panels 20 are arranged in asingle layer against the frame members, such that the longitudinal sidesof adjacent panels 20 abut, and such that the backing sheets 60 abut theframe members.

Interior finishing materials (not shown), such as for example drywallboards, may be fastened to interior-facing sides of thevertically-oriented frame members 72, and exterior finishing materials(not shown), such as for example masonry or brickwork, may beconstructed adjacent the exterior-facing surface of the wall 70.

As will be appreciated, because the continuous fibers 40 extend betweendiagonally opposite corners and between adjacent edges of the first face24, the continuous fibers 40 improve the overall structural rigidity ofthe panel 20, and increase the strength of the panel 20 along itsdiagonal directions and thereby provide diagonal bracing to the panel20. As a result, use of the panel 20 in an exterior wall advantageouslyenables the exterior wall to satisfy building codes that requireexterior walls to include diagonal bracing.

As will be appreciated, the generally unitary construction of the panel20 comprises diagonal bracing, thermal insulation and a moisture barrierwithin a single unit. Thus, during construction of an exterior wall,fastening of a single panel 20 to frame members effectively results inthe simultaneous fastening of diagonal bracing, thermal insulation and amoisture barrier. As will be understood, this advantageously reduces theamount of on-site labour needed to construct the wall. Additionally, thegenerally unitary construction advantageously enables diagonal bracing,thermal insulation and the moisture barrier to be transported as asingle unit, thereby facilitating, and lowering the associated cost of,materials delivery to the construction site.

In this embodiment, the reinforced insulating panel 20 is manufacturedby providing a molded insulating foam slab 22 having desired dimensions,and by providing a reinforcement sheet 30. The reinforcement sheet 30 isaffixed to the first face 24 of the insulating foam slab 22 by peeling adisposable backing film (not shown) disposed on the second film 34 toexpose a glue layer (not shown), orienting the reinforcement sheet 30such that the continuous fibers 40 therein have a suitable diagonalorientation relative to the insulating foam slab 22, and then applyingthe oriented reinforcement sheet 30 such that the glue layer is broughtinto contact with the first face 24 of the insulating foam slab 22. Thebacking sheet 60 is affixed to the second face 26 of the insulating foamslab 22 by peeling a disposable backing film (not shown) disposed on thebacking sheet 60 to expose a glue layer (not shown), and then byapplying the backing sheet 60 such that the glue layer is brought intocontact with the second face 26 of the insulating foam slab 22. Any ofthe reinforcement sheet 30 and the backing sheet 60 may be cut tosuitable size, if needed, either prior to or after being affixed to theinsulating foam slab 22.

The reinforced insulating panel is not limited to the configurationdescribed above, and in other embodiments, other configurations may beused. For example, although in the embodiment described above, the panelcomprises a reinforcement sheet fastened to the first face of theinsulating foam slab and a backing sheet fastened to the second face, inother embodiments, the panel may alternatively not comprise any backingsheet. In one such embodiment, the second face of the insulating foamslab may alternatively define a surface of the panel. In still otherembodiments, the panel may alternatively comprise two (2) reinforcementsheets, namely a first reinforcement sheet fastened to the first face ofthe insulating foam slab and a second reinforcement sheet fastened tothe second face of the insulating foam slab.

Although in the embodiment described above, the backing sheet comprisesa single film, in other embodiments, the backing sheet may alternativelycomprise a plurality of films.

Although in the embodiment described above, the reinforcement sheetcomprises a plurality of continuous fibers disposed between the firstfilm and the second film in a “sandwich” configuration, in otherembodiments, the reinforcement sheet may alternatively comprise only asingle film and the continuous fibers. In one such embodiment, thecontinuous fibers may be disposed between the single film and theinsulating foam slab. In another such embodiment, the single film may bedisposed between the continuous fibers and the insulating foam slab.

Although in the embodiment described above, the first film, the secondfilm and the backing sheet are fabricated of polypropylene, in otherembodiments, one or more of the first film, the second film and thebacking sheet may alternatively be fabricated of another suitablematerial, such as for example, polyester. In a related embodiment, oneor more of the first film, the second film and the backing sheet mayalternatively be fabricated of a polymeric fibrous material, such as forexample Tyvek®, manufactured by Dupont® of Wilmington, Del., U.S.A. In arelated embodiment, one or more of the first film, the second film andthe backing sheet may alternatively be metallized for providingreflectivity of light having wavelengths in the infrared range forproviding additional thermal insulation.

One or more of the first film, the second film and the backing sheet maycomprise perforations for reducing or preventing moisture accumulationwithin the panel.

Although in the embodiment described above, the reinforcement sheet andthe continuous fibers therein cover the entire face of the insulatingfoam slab, in other embodiments, the reinforcement sheet and thecontinuous fibers may cover only a portion of the face of the insulatingfoam slab.

Although in the embodiment described above, the continuous fibers arearranged as two (2) sets of parallel continuous fibers, in otherembodiments, the continuous fibers may alternatively be arranged as onlyone (1) set of parallel continuous fibers that are oriented in adiagonal orientation, such that the parallel continuous fibers extendbetween diagonally opposite corners of a face of the insulating foamslab and between adjacent edges of the face of the insulating foam slab.In still other embodiments, the continuous fibers may alternatively bearranged as more than two (2) sets of parallel continuous fibers, withfirst and second sets of parallel continuous fibers each being orientedin a respective diagonal orientation, such that the parallel continuousfibers of each of the first and second sets extend between diagonallyopposite corners of a face of the insulating foam slab and betweenadjacent edges of the insulating foam slab, and with one or moreadditional sets of parallel continuous fibers, with the fibers of eachadditional set being oriented in a different respective orientation,such as for example in a longitudinal orientation, in a transverseorientation, or in any other orientation therebetween. Here, it will beunderstood that in the “longitudinal orientation” the fibers extendbetween the transverse edges of the face of the insulating foam slab,while in the “transverse orientation” the fibers extend between thelongitudinal edges of the face of the insulating foam slab. As anexample, in one embodiment, the continuous fibers may alternatively bearranged as four (4) sets of parallel continuous fibers, with first andsecond sets of parallel continuous fibers each being oriented in arespective diagonal orientation, such that the parallel continuousfibers of each of the first and second sets extend between diagonallyopposite corners of a face of the insulating foam slab and betweenadjacent edges of the insulating foam slab, and with a third set ofparallel continuous fibers being oriented in the longitudinalorientation and with a fourth set of parallel continuous fibers beingoriented in the transverse orientation.

Although in the embodiment described above, the continuous fibers arearranged as two (2) sets of parallel continuous fibers, in otherembodiments, the continuous fibers may alternatively be arranged as oneor more sets of non-parallel continuous fibers. For example, in one suchembodiment, the continuous fibers may alternatively be arranged as afirst set of non-parallel continuous fibers and a second set ofnon-parallel continuous fibers, with fibers of each set being generallyoriented in a respective diagonal orientation, and with fibers of eachset being sized so as to extend diagonally across the first face.

Although in the embodiment described above, the fibers within each setof parallel continuous fibers have a pitch of about 0.25 inches, inother embodiments, the fibers may alternatively have a pitch less thanor greater than 0.25 inches. In one embodiment, the pitch of the fiberswithin each set of parallel continuous fibers may be from about 0.25inches to about 0.40 inches. In still other embodiments, the pitch ofthe fibers within one set may alternatively be different from the pitchof the fibers of another set.

Although in the embodiment described above, the continuous fibers withineach set and of parallel continuous fibers are uniformly spaced, inother embodiments, at least some of the continuous fibers within one ormore sets may alternatively be variably spaced, and may thereby have avariable pitch.

Although in the embodiment described above, the fibers define an angleof about 26.6 degrees relative to the longitudinal side of the panel, inother embodiments, the fibers of one or more sets may alternatively eachdefine a different angle relative to the longitudinal side of the panel.For example, in one embodiment, the fibers may alternatively define anangle of about 45 degrees relative to the longitudinal side of thepanel.

Although in the embodiment described above, the fibers of the first setdefine an angle of about 53.1 degrees relative to the fibers of thesecond set, in other embodiments, the fibers of the first set mayalternatively define a different angle relative to the fibers of thesecond set. For example, in one embodiment, the fibers of the first setmay alternatively define an angle of about 90 degrees relative to thefibers of the second set.

Although in the embodiment described above, the continuous fibers arefabricated of glass, in other embodiments, one or more continuous fibersmay alternatively be fabricated of another suitable material, such asfor example, metal, polymer, plastic, wool, and the like.

Although in the embodiment described above, the insulating foam slab isfabricated of molded expanded polystyrene (EPS) foam, in otherembodiments, the insulating foam slab may alternatively be fabricated ofanother suitable material, such as for example, extruded polystyrenefoam (XPS), polyurethane foam, and the like. It will be understood thatthe insulating foam slab is not limited to dimensions of 4 feet×8 feet×1inch, and may alternatively have other dimensions.

Although in the embodiment described above, the insulating foam slab hasa longitudinal shape, in other embodiments, the insulating foam slab mayalternatively have a different shape. For example, in one embodiment,the insulating foam slab may alternatively have a square shape.

Although in the embodiment described above, the panels are fastened suchthat the backing sheets abut the frame members of the wall, in otherembodiments, one or more panels may alternatively be fastened such thatthe reinforcement sheets abut the frame members of the wall. Inembodiments in which the panel does not comprise any backing sheet andin which the second face of the insulating foam slab defines a surfaceof the panel, one or more panels may alternatively be fastened such thatthe second face of the insulating foam slab abut the frame members ofthe wall.

Although in the embodiment described above, the panel is configured tobe fastened to exterior-facing sides of frame members of an exteriorwall of a building constructed using the light-frame constructionmethod, it will be understood that the reinforcing wall panel is notlimited to use in exterior walls, or to walls and/or buildingsconstructed using the light frame construction method.

It will be understood that the method of manufacturing the reinforcedinsulating panel is not limited to the method described above, and inother embodiments, other approaches may be used. For example, themanufacturing method may further include molding the insulating foamslab, such as for example by filling a mold with expandable polystyrenebeads, and heating the mold and/or the expandable polystyrene beads toform the insulating foam slab. The molded insulating foam slab may thenbe cut, as needed, to the desired dimensions after molding. Thereinforcement sheet may alternatively not comprise a glue layer that isexposed by peeling a disposable backing film, but rather a glue layermay be applied to the first face of the insulating foam slab, to thesecond film of the reinforcement sheet, or to both, prior to applyingthe oriented reinforcement sheet to the insulating foam slab. Thebacking sheet may alternatively not comprise a glue layer that isexposed by peeling a disposable backing film, but rather a glue layermay be applied to the second surface of the insulating foam slab, to thebacking sheet, or to both, prior to applying the backing sheet to theinsulating foam slab.

Providing the reinforcement sheet may further comprise forming thereinforcement sheet, whereby the forming comprises disposing thecontinuous fibers and at least one glue layer between the first film andthe second film, and applying suitable pressure thereto so as to jointhe continuous fibers and the first and second films. Alternatively,forming the reinforcement sheet may comprise disposing the continuousfibers and at least one glue layer against a film, and applying suitablepressure thereto so as to join the continuous fibers and the film. Inboth such forming approaches, the forming may comprise, prior to thedisposing, orienting the continuous fibers so as to have a suitablediagonal orientation.

Still other manufacturing approaches are possible. For example, in otherembodiments, the reinforced insulating panel may be manufactured byaffixing the second film to the first face of the insulating foam slab,by disposing a glue layer to the surface of the affixed second film, andthen applying the continuous fibers to the glue layer disposed on thesecond film. In such an embodiment, the continuous fibers would beapplied to the glue layer disposed on the second film in a suitablediagonal orientation, and may be applied either individually or as twoor more continuous fibers simultaneously. A first film may then beapplied to the plurality of continuous fibers disposed on the glue layerof the second film, and an additional glue layer may be disposedtherebetween if necessary.

Still other manufacturing approaches are possible. For example, in otherembodiments, the reinforced insulating panel may be manufactured bydisposing a glue layer to the first surface of the insulating foam slab,and then applying the continuous fibers to the glue layer disposed onthe insulating foam slab. In such an embodiment, the continuous fiberswould be applied to the glue layer disposed on the insulating foam slabin a suitable diagonal orientation, and may be applied eitherindividually or as two or more continuous fibers simultaneously. A filmis then applied to the plurality of continuous fibers disposed on theglue layer of the insulating, and an additional glue layer may bedisposed therebetween if necessary.

Although embodiments have been described above with reference to theaccompanying drawings, those of skill in the art will appreciate thatvariations and modifications may be made without departing from thescope thereof as defined by the appended claims.

1. A reinforced insulating panel comprising: an insulating foam slabhaving two opposing faces; and a reinforcement sheet disposed on onlyone of said two opposing faces of the insulating foam slab, thereinforcement sheet comprising a plurality of continuous fibersextending diagonally across the face of the insulating foam slab.
 2. Thereinforced insulating panel of claim 1, wherein the continuous fibersextend between diagonally opposite corners of the face and betweenadjacent edges of the face.
 3. The reinforced insulating panel of claim1, wherein said reinforcement sheet comprises at least one film and saidcontinuous fibers.
 4. The reinforced insulating panel of claim 3,wherein said at least one film comprises a single film.
 5. Thereinforced insulating panel of claim 4, wherein said continuous fibersare disposed between said single film and said insulating foam slab. 6.The reinforced insulating panel of claim 4, wherein said single film isdisposed between said continuous fibers and said insulating foam slab.7. The reinforced insulating panel of claim 4, wherein said single filmis metallized.
 8. The reinforced insulating panel of claim 3, whereinsaid at least one film comprises a first film and a second film, saidcontinuous fibers being disposed between the first film and the secondfilm.
 9. The reinforced insulating panel of claim 8, wherein at leastone of the first film and the second film is adhered to the insulatingfoam slab.
 10. The reinforced insulating panel of claim 8, wherein atleast one of the first film and the second film is metallized.
 11. Thereinforced insulating panel of claim 1, wherein said reinforcement sheetis disposed on a first face of the insulating foam slab, and whereinsaid panel further comprises: a backing sheet disposed on a second faceof the insulating foam slab.
 12. (canceled)
 13. The reinforcedinsulating panel of claim 1, wherein said reinforcement sheet isdisposed on a first face of the insulating foam slab, and wherein saidpanel further comprises: another reinforcement sheet disposed on asecond face of the insulating foam slab, said another reinforcementsheet comprising a plurality of continuous fibers extending diagonallyacross the second face of the insulating foam slab.
 14. The reinforcedinsulating panel of claim 1, wherein said plurality of continuous fiberscomprises parallel continuous fibers.
 15. The reinforced insulatingpanel of claim 14, wherein said parallel continuous fibers are uniformlyspaced.
 16. The reinforced insulating panel of claim 14, wherein saidparallel continuous fibers have a pitch of less than about 0.4 inches.17. The reinforced insulating panel of claim 14, wherein said parallelcontinuous fibers are arranged as a diagonal grid.
 18. The reinforcedinsulating panel of claim 14, wherein said parallel continuous fiberscomprise a first set of parallel continuous fibers and a second set ofparallel continuous fibers, said first set of parallel continuous fibershaving a different diagonal orientation than said second set of parallelcontinuous fibers.
 19. The reinforced insulating panel of claim 1,wherein said continuous fibers are fabricated of any of glass, metal,polymer, plastic, and wool.
 20. A method of manufacturing a reinforcedinsulating panel, the method comprising: providing an insulating foamslab having two opposing faces; providing a reinforcement sheet, thereinforcement sheet comprising a plurality of continuous fibers; andaffixing the reinforcement sheet to only one of said two opposing facesof the insulating foam slab such that the continuous fibers are orienteddiagonally across the face of the insulating foam slab.